Programmable device provided in a production environment for assisting an operator

ABSTRACT

A programmable device (D) arranged in a production environment, to assist an operator (O) in performing manual assembly operations carried out by the operator (O), particularly during assembly operations performed on pieces (P) transported by pallets ( 5 ) in a production line ( 1 ). The device (D) comprises an assembly means usable by the operator (O), a lighting device ( 4 ) for lighting a work area in which the operator (O) works, a sensor ( 6 ) configured to detect the position of the assembly means, an input device ( 10 ) usable by the operator, and an electronic control system ( 8 ) configured to memorize a learning sequence including a sequence of manual assembly operations.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application is a national stage application, filed under 35 U.S.C.§ 371, of International Patent Application No. PCT/IB2018/0055497, filedJul. 24, 2018, and Italian Patent Application No. 102017000085336, filedJul. 26, 2017, which are incorporated by reference in their entirely.

TECHNICAL FIELD

The present invention relates to programmable devices provided in aproduction environment for assisting an operator. In particular, theinvention relates to a programmable device designed to assist anoperator in performing manual assembly operations, for example, assemblyoperations carried out on pieces transported by pallets in a productionline.

BACKGROUND

In modern production lines, particularly in the automotive sector, partsor basic components advance along a pallet transport line through aseries of assembly stations, where further parts and components areassembled in succession on each basic component carried by a palletprovided for the transport of parts or components. Currently, a solutionin use that is alternative to the one indicated above to transport partsor components is that of configuring a plurality of Automated GuidedVehicles (AGVs), with the pieces to be assembled on board, which movewithin the production environment. The assembly operations are performedmanually by operators with the help of automated assembly systems. Inproduction environments of this type, production must be maximized,ensuring that the operators perform assembly operations quickly andcorrectly. Fulfilling this requirement in an optimal way is not easysince the sequence of assembly operations, which the operators mustperform, varies according to the pieces or components transported by thepallets, which, in turn, vary according to the production request.

Examples of systems provided in a production environment to assist anoperator in performing manual assembly operations are described in thedocuments US 2012/0062725 A1, U.S. Pat. No. 9,372,278 B2 and US2013/325155 A1.

SUMMARY

The object of the present invention is to provide a programmable deviceof the type indicated above, which is particularly effective in ensuringthat the assembly operations are carried out correctly by the operators,and that it is simple and intuitive to use.

A further object of the invention is to achieve the aforesaid objectiveswith a device that allows rapid adaptation with respect to the sequenceof operations that the operator must perform, in the event that the needto change the sequence of operations arises.

In view of achieving these objects, the invention relates to aprogrammable device arranged in a production environment, to assist anoperator in the execution of manual assembly operations performed bysaid operator in said production environment, particularly in the courseof assembly operations performed on pieces transported by pallets in aproduction line, said device comprising:

-   -   an assembly means usable by said operator for performing said        manual assembly operations on said pieces transported by said        pallets, said assembly means being in particular a tool or the        operator's hands directly;    -   at least one input device usable by said operator;    -   at least one lighting device having at least one light source        for illuminating a work area in which said operator works, said        lighting device being configured to indicate the correct        sequence of manual operations to be carried out on said pieces,        carried by said pallets, to said operator;    -   at least one sensor configured to detect the spatial coordinates        of said assembly means with reference to said work area; and    -   an electronic control system operatively connected to said input        device, to said at least one lighting device and to said at        least one sensor, said electronic control system being        configured to memorize a learning sequence including a sequence        of said manual assembly operations, in order to register the        position of said assembly means during the execution—in real        time—by said operator (O) of a work cycle including said        sequence of operations, wherein said learning sequence comprises        the following steps:    -   said electronic control system provides a command to said sensor        to continuously observe said work area, said operator and said        assembly means in order to detect the spatial coordinates of        said assembly means;    -   said electronic control system receives said spatial coordinates        of said assembly means detected by said sensor and communicates        said coordinates to said lighting device;    -   said lighting device projects a graphic instruction onto said        work area, in particular a symbol, by means of said light        source, at the spatial coordinates of said assembly means;    -   said electronic control system receives a request to register        the position of said assembly means following the actuation of        said input device;    -   said operator passes to a subsequent operation of said learning        sequence or activates said input device to terminate said        learning sequence.

Thanks to the characteristics indicated above, the programmable deviceaccording to the present invention is particularly flexible with respectto production requirements, as it is possible to start a new learningsequence in a simple and intuitive way, whenever the sequence ofoperations that the operator must perform varies. Moreover, this deviceis suitable for achieving the predetermined objects both in the case inwhich the assembly operations are carried out by the operator's hands,and in the case in which the operator uses an assembly tool forassembling the components.

The electronic control system of the device according to the inventionis also configured to collaborate with the operator to perform the workcycle according to the learning sequence carried out, wherein:

-   -   said electronic control system regulates the light beam of said        lighting device at the registered position of said assembly        means;    -   said lighting device illuminates said work area, in particular        by projecting said symbols by means of said light source;    -   said operator positions said assembly means at the position        indicated by said lighting device and actuates an input for the        start of the work cycle;    -   said electronic control system requires said sensor to locate        said assembly means;    -   said sensor calculates the spatial coordinates of said assembly        means;    -   said electronic control system receives the spatial coordinates        of said assembly means from said sensor and verifies the        correspondence between the position of said assembly means and        said symbols;    -   said operator verifies the correspondence result that has        occurred and performs an assembly operation indicated by said        symbol.

In the case in which the assembly means are in the form of a tool, theinput device is arranged on the tool in the form of a recording buttonmanually operable by the operator to request a recording of the positionof the tool, to terminate the learning sequence or to start the workcycle.

In the case in which manual operations are performed directly by theoperator's hands and the assembly tool is, therefore, not present, theaforesaid input device can be produced in the form of a device arrangedon the wrist of the operator (for example, a SmartWatch) or a devicearranged on the operator's arm (for example, a SmartPhone or Tablet). Anadditional alternative solution that can be implemented to produce theinput device is that of providing a voice recognition device (forexample, a microphone on the throat that is immune to environmentalnoise).

In a preferred embodiment, said sensor is a system of inertial sensorsarranged to determine the position of the assembly means, in such a waythat said system is able to detect the position in space of saidassembly means.

Additional variations to the embodiments indicated above are describedin the description which follows and in the attached claims.

The present description is also directed at a method for assisting anoperator during manual assembly operations conducted in a productionenvironment, particularly during assembly operations performed on piecestransported by pallets in a production line, wherein said operatorcooperates with a programmable device having the characteristicsdescribed in detail in the following part of the present description.

BRIEF DESCRIPTION OF THE DRAWINGS

Further characteristics and advantages of the present invention willbecome apparent from the description that follows with reference to theattached drawings, provided purely by way of non-limiting example,wherein:

FIG. 1 is a schematic view of a preferred embodiment of the deviceaccording to the present invention;

FIG. 2 is an example of a production line with which the deviceaccording to the present invention can be associated;

FIG. 3 illustrates an example of a pallet for transporting pieces onwhich assembly operations are performed; and

FIG. 4 illustrates an example of an assembly tool with which an operatorcarries out assembly operations.

DETAILED DESCRIPTION

In the following description, various specific details are illustratedaimed at a thorough understanding of the embodiments. The embodimentscan be implemented without one or more of the specific details, or withother methods, components, materials, etc. In other cases, knownstructures, materials or operations are not shown or described in detailto avoid obscuring various aspects of the embodiments. The referencesused here are only for convenience and do not, therefore, define thefield of protection or the scope of the embodiments.

In the schematic view of FIG. 1, the reference D indicates—in itsentirety—a preferred embodiment of a programmable device according tothe present invention, to assist an operator O in performing manualassembly operations in a production environment. In the embodimentillustrated in the drawings, the invention is directed at a device D forassisting an operator O, capable of performing assembly operations onpieces P transported by pallets 5 which move along a production line 1.

With reference to FIG. 2, numeral 1 indicates—in its entirety—aproduction line with which the device D according to the invention canbe associated. The production line 1 is of the continuous motion typeand comprises a plurality of assembly stations 2 arranged in series witheach other, in which an operator O is assigned to each assembly station2. The line 1 includes a chain conveyor device 3 mounted adjacent to theassembly stations 2 and arranged to allow the transport of a pluralityof pallets 5 along the line 1. Each pallet 5 is arranged, for example,to carry a base piece (for example a cylinder head) on which theoperator O manually assembles further components. All the detailsrelating to a continuous motion production line as described above arepart of a European patent application already proposed by the sameApplicant.

Of course, the production line illustrated in FIG. 2 and described aboveis provided purely by way of example, since the present invention isalso applicable to other types of production environments, for example,a stop & go line, a single production cell or an environment populatedby a plurality of AGVs.

Returning to the example illustrated in FIG. 2, an operator O isassigned to each of the aforesaid assembly stations 2, who works on thepieces transported by the pallets 5 which move continuously in front ofhim. Each operator O works on all the pallets 5 that pass through theassembly station 2 that he is manning. For each pallet 5 that movescontinuously through the station, the operator performs a plurality ofassembly operations on the pieces P transported by the pallets 5, movingby the side of the line 1 in order to follow the pallet 5 in itsmovement. If all the manual operations are carried out correctly andwithin the expected time, when the pallet—following its continuousmovement—leaves the aforesaid assembly station, the component carried bythe pallet contains all the additional components correctly mounted inthe station.

In a concrete embodiment of the device D according to the invention, thepallet 5 is produced according to that illustrated in the patentapplication EP 15153558 by the same Applicant, and the device D isassociated with each assembly station 2.

According to an important characteristic of the invention, the device Dis arranged to assist an operator O, capable of performing assemblyoperations on pieces P, both in the case in which the operator performsoperations by means of an assembly tool, and in the case in which theoperator uses his hands directly to perform these operations.

In the following description, the different elements of the device willnow be described.

In the embodiment illustrated in FIG. 1, the device D is illustratedschematically in the case in which the operator carries out the assemblyoperations by means of a tool. According to this Figure, the device Dcomprises an assembly tool 11 usable by the operator O for carrying outthe manual assembly operations on the parts P transported by the pallets5. A concrete embodiment example of an assembly tool is illustrated inFIG. 4, which illustrates a screwdriver tool 11. This screwdriver isillustrated purely by way of example, since, in the case in which theoperator uses a tool for carrying out assembly operations, it can alsobe implemented in other forms (for example, a torque wrench).

Returning to FIG. 1, the device D further comprises at least onelighting device 4 having at least one light source for illuminating awork area in which the operator O works.

As will be explained in greater detail below, the lighting device 4 isconfigured to indicate the correct sequence of manual operations to becarried out on the pieces P, transported by the pallets 5, to theoperator O.

According to a technique known per se, the lighting device 4 can be, forexample, a two-dimensional laser device, designed to generate apunctiform laser beam with which an optical diffraction element isinterposed to project an image, such as, for example, a motif with dotsor crosses or stripes.

To overcome some technical limitations of the two-dimensional laserdevice, the lighting device 4 can be alternatively produced in the formof a three-dimensional laser scanner (also in this case according to atechnique known per se). In the case of three-dimensional laserscanners, a punctiform laser beam is deflected by a pair of mirrors ongalvanometers to create symbols and/or writing. Moreover, by usingthree-dimensional laser scanners, it is also possible to specify thedistance between the piece P and the lighting device 4, so as to keepthe size of the projected image constant at the various points of thepiece P. In the light of what has been described above, the use ofthree-dimensional laser scanners allows more complex graphicinstructions to be obtained with respect to the instructions provided bythe two-dimensional laser devices, such as arrows, concentric circlesand writing.

The device also comprises at least one input device which can be used bythe operator (described in greater detail in the following description)and at least one sensor 6 configured primarily for detecting the spatialcoordinates of the assembly tool 11 or the hands of the operator O withreference to the work area in which the operator O works.

The device D also comprises an electronic control system 8 operativelyconnected by means of communication lines L to the input device, to thelighting device 4, and to the sensor 6. The elements of the device D canalso be connected to the electronic control system 8 by means of awireless connection. In the embodiment illustrated in FIG. 1, in whichthe operator uses the tool 11 for carrying out the assembly operationson the pieces, the tool 11 is provided with a control unit 9 whichcommunicates with the general electronic control system 8 by means of awireless connection.

According to an essential characteristic of the device according to thepresent invention, the electronic control system 8 is configured tomemorize a learning sequence, including a sequence of manual assemblyoperations, in order to register the position of the tool 11 or thehands of the operator O during a work cycle.

Memorizing this learning sequence is necessary to ensure that the deviceD functions in such a way as to indicate to the operator O, during awork cycle, the correct sequence of operations to be performed on thebase pieces P transported by the pallets 5, cooperating with theoperator O in order to guarantee the correctness of the individualoperations performed.

The learning sequence performed by the device D comprises the followingsteps:

-   -   the electronic control system 8 provides a command to the sensor        6 to continuously observe the work area, the operator O and, if        present, also the tool 11, in order to detect the spatial        coordinates of the tool 11 or the hands of the operator O;    -   the electronic control system 8 receives the spatial coordinates        of the tool 11 or the hands of the operator O detected by the        sensor 6 and supplies the coordinates to the lighting device 4;    -   the lighting device 4 projects a graphic instruction onto the        work area, for example, a symbol or some writing, by means of        the light source, at the spatial coordinates of the tool 11 or        the hands of the operator O detected by the sensor 6;    -   the electronic control system 8 receives a request to register        the position of the tool 11 or, in the absence of it, the        position of the hands of the operator O, following a recording        input operated by the aforesaid input device;    -   the operator O passes to a subsequent operation of the learning        sequence or activates the aforesaid input device to terminate        said learning sequence.

In practice, this operating mode of the device D, in which the lightingdevice 4 follows the position of the hands or of the tool 11 during theexecution of the operations constituting a work cycle, is at the basisof memorizing the learning sequence of the device D.

Thanks to the fact that the device D is configured to record theaforesaid learning sequence during the real-time execution of theoperations constituting a work cycle, the device D has the advantage ofrapidly adapting to a new sequence of operations that the operator mustperform, and thus be fast and intuitive for the operator.

To ensure the correct operation of the device D, the sensor 6 and thelighting device 4 must share the same reference system, so that the x,y, z coordinates of the position of the tool 11 (or in the absencethereof, of the position of the operator's hands) can be sent from theelectronic control system 8 to the lighting device 4, and the projectedlight is directed to the same position of the tool 11.

To be able to share the same reference system between the sensor 6 andthe lighting device 4, the sensor 6 and the lighting device 4 areprovided with their own calibration method configured to position theorigin of a shared reference system in the middle of the pallet thatcarries the piece P on which the manual assembly operations must becarried out.

Based on the roto-translation matrices with respect to the origin of thesensor reference system (MOS) and the illumination source of thelighting device (MOP), it is possible for the electronic control system8 to determine the relative position of the sensor 6 with respect to thelighting device 4, by means of the relation: MPS=MOPT*MOS.

The calibration method is carried out by the sensor 6 and by thelighting device 4 during installation of the device D, under thedirection of the electronic control system 8.

In the case wherein a variation of the position of the pallet occurs(for example, for production needs), in order to re-position the originof the shared reference system to the center of the new pallet position,it is sufficient that either the sensor 6 or the lighting device 4re-executes the calibration method, and that the electronic controlsystem 8 takes into account the result of the new calibration formanaging the coordinates read by the sensor 6 and sent to the lightingdevice 4. To correctly implement this management, it is possible to usethe relation MPS indicated above or the relation between the lastcalibration (with which the new origin of the reference system O′ isobtained) and that performed during installation (with which the originO was obtained). In the case of recalibration performed by the lightingdevice 4, this relationship is: MO′O=MO′P*MOPT. The roto-translationmatrix MO′O is applied to the coordinates of the positions read by thesensor 6 in order to be able to communicate with the known coordinatesat the lighting device 4.

In the case in which assembly operations are performed by means of theaforesaid tool 11, the input device for recording or terminating theaforesaid learning sequence is preferably manually operated by theoperator O, and may consist of a button 10 arranged on the tool 11 (asillustrated in FIG. 1). Alternatively, a manually operable input can beconstituted, for example, by a pedal arranged in the work area.

In the case in which manual operations are performed directly by theoperator's hands and this tool is therefore not present, the aforesaidinput device can be produced in the form of a device arranged on thewrist of the operator (for example a SmartWatch) or a device arranged onthe operator's arm (for example a SmartPhone or Tablet).

A further alternative solution that can be implemented to produce theaforesaid input device is that of providing a voice recognition device(for example, a microphone on the throat that is immune to environmentalnoise).

A further alternative solution that can be implemented to produce theaforesaid input device is that of providing an input system based on therecognition by the sensor 6 of some postures of the fingers of theoperator's hands such as, for example, an open hand, a closed hand or aclosed hand with some fingers open. In practice, these hand postures ofthe operator O can be combined with macro-commands for the device D,such as, for example, the start or stop of a work cycle or even commandsfor advancing or retroceding a single operation forming part of thesequence of operations constituting the work cycle.

The sensor 6 can also be made according to different known solutions.For example, it can be an infrared vision system or a visible lightvision system. Other possible solutions for producing the sensor 6 arean ultra-sound system or an infrared vision system with active orpassive markers. In these last three cases, the sensor 6 includes (asshown in FIG. 1) an emission unit 7 arranged on the tool 11, and areceiving unit 60 arranged above the work area for receiving informationfrom the said emission unit 7, in such a way that the sensor 6 is ableto detect the position in space of the tool 11.

Alternatively to the vision or ultrasound systems, the tool 11 can beprovided with a plurality of inertial sensors (accelerometers,gyroscopes and magnetometers), in such a way that the sensor 6,receiving the signal detected by these sensors, calculates the positionin space of the tool 11.

As mentioned previously, the device D is configured for collaboratingwith the operator O to indicate the correct sequence of assemblyoperations to the operator. According to a further importantcharacteristic of the invention, the electronic control system 8 isconfigured to perform a work cycle according to the previously indicatedlearning sequence, wherein:

-   -   the electronic control system 8 regulates the light beam of the        lighting device 4 at the position of the tool 11 or the hands of        the operator O;    -   the lighting device 4 illuminates the work area, in particular,        by projecting symbols by means of the light source;    -   the operator O positions the tool 11 or his hands at the        position indicated by the lighting device 4 and actuates an        input for the start of the work cycle;    -   the electronic control system 8 requires the sensor 6 to locate        the tool 11 or the hands of the operator O directly;    -   the sensor 6 calculates the spatial coordinates of the tool 11        or the hands;    -   the electronic control system 8 receives the spatial coordinates        of the tool 11 or the hands of the operator from the sensor 6,        and verifies the correspondence between their position and the        symbols; and    -   the operator O verifies the correspondence result that has        occurred and performs an assembly operation indicated by said        symbol.

To ensure the correct operation of the device D, also during theexecution of a work cycle, it is necessary that the sensor 6 and thelighting device 4 share the same reference system (following thecalibration method previously indicated), so that the light beam of thelighting device 4 is directed by the lighting device 4 to the x, y, zcoordinates of a working position, and the sensor 6 can read thepresence of the assembly means in the same position.

In practice, this operating mode of the device D, in which the sensor 6detects the position of the assembly means following the graphicinstructions projected by the lighting device 4 onto the work area, isthe basis of the operation of the device D during the actual executionof a work cycle by an operator. As said previously, examples of lightsymbols projected by said lighting device can be very simple motifs ormore complex figures depending on the type of lighting device.

The present invention is also directed at a method for assisting anoperator O during assembly operations carried out in a productionenvironment, in which the operator O cooperates with the programmabledevice D according to the present invention.

In the embodiment, the device D comprises a single sensor 6, a singlelighting device 4 and a single tool 11, but a plurality of theseelements can also be provided depending on the production environmentwith which the present device is associated.

Thanks to the characteristics indicated above, the device according tothe invention assists an operator in performing manual assemblyoperations, ensuring that the assembly operations are carried outcorrectly by the operators, by means of a device which is simple andintuitive to use, and which allows rapid adaptation to the sequence ofoperations that the operator must perform each time the need to changethis sequence arises.

Of course, without prejudice to the principle of the invention, thedetails of construction and the embodiments may vary widely with respectto those described and illustrated purely by way of example, withoutdeparting from the scope of the present invention.

The invention claimed is:
 1. A method of assisting an operator (O) inperforming manual assembly operations carried out by said operator (O)in a production environment, the operator (O) is assisted by aprogrammable device (D) arranged in said production environment, themethod comprising the steps of: providing the programmable device (D)comprising: an assembly means usable by said operator (O) for performingsaid manual assembly operations on said pieces (P) transported by saidpallets (5), said assembly means comprising one of a tool (11) or theoperator's (O) hands directly; at least one input device usable by saidoperator (O); at least one lighting device (4) having at least one lightsource operable to illuminate a work area in which said operator (O)works, said lighting device (4) operable to indicate a correct sequenceof manual operations to be carried out on said pieces (P), transportedby said pallets, to said operator (O); at least one sensor (6) operableto detect spatial coordinates of said assembly means (11) with referenceto said work area; and an electronic control system (8) operativelyconnected to said at least one input device, to said at least onelighting device (4) and to said at least one sensor (6), said electroniccontrol system (8) operable to memorize in real time a learning sequenceof said manual assembly operations by said operator (O) forming a workcycle, wherein memorizing said learning sequence comprises the followingsteps: providing by said electronic control system (8) a command to saidsensor (6) to continuously observe said work area, said operator (O) andsaid assembly means and detecting the spatial coordinates of saidassembly means and to continually follow a position of the assemblymeans during execution of the manual assembly operations constitutingthe work cycle; receiving by said electronic control system (8) saidspatial coordinates of said assembly means detected by said sensor (6)and communicating said received spatial coordinates to said lightingdevice (4); projecting by said lighting device (4) light source agraphic instruction in said work area at the spatial coordinates of saidassembly means detected by said sensor (6); receiving by said electroniccontrol system (8) a request to record the position of said assemblymeans following an actuation of said at least one input device; passingby said operator (O) to a subsequent operation of said learning sequenceor activating said at least one input device to terminate said learningsequences; assisting by the electronic control system (8) the work cycleaccording to the previously recorded learning sequence, assisting thework cycle comprising: regulating by said electronic control system (8)a light beam of said lighting device (4) at the recorded position ofsaid assembly means; illuminating by said lighting device (4) said workarea, by projecting a graphic instruction by means of said light source;positioning by said operator (O) said assembly means at the recordedposition indicated by said lighting device (4) and actuating the atleast one input device for the start of the work cycle; requiring bysaid electronic control system (8) said sensor to detect said assemblymeans; calculating by said sensor (6) the spatial coordinates of saiddetected assembly means; receiving by said electronic control system (8)the spatial coordinates of said assembly means from said sensor;verifying by the electronic control system (8) a correspondence betweenthe spatial coordinates of the detected assembly means and the spatialcoordinates of said recorded position; and verifying by said operator(O) a correspondence result that has occurred, wherein the operator (O)performs the manual assembly operations indicated by said graphicinstruction.
 2. The method of claim 1 wherein said assembly meanscomprises said tool (11), said at least one input device is arranged onsaid tool (11) in the form of a recording button (10) manually operableby said operator (O), to request a recording of the position of saidtool (11), to terminate said learning sequence or to start said workcycle.
 3. The method of claim 1 wherein said assembly means comprisesthe hands of the operator, said at least one input device is arranged ona wrist of the operator (O) and comprising a Smart-Watch-type devicemanually operable by said operator (O), to request a recording of theposition of the hands, to terminate said learning sequence or to startsaid work cycle.
 4. The method of claim 1 wherein said assembly meanscomprise the hands of the operator, said at least one input devicecomprises a voice recognition device operable by means of voiceinstructions by said operator (O), to request a recording of theposition of the hands, to terminate said learning sequence or to startsaid work cycle.
 5. The method of claim 1 wherein said assembly meanscomprises said tool (11), said tool (11) is one of connected directly tosaid electronic control system (8) or indirectly by means of a controlunit (9) integrally provided with said tool (11).
 6. The method of claim2 wherein said sensor (6) comprises an infrared sensor that includes anemission unit (7) arranged on said tool (11) and a receiving unit (60)arranged above said work area, operable to receive information from saidemission unit (7), in such a way that said sensor (6) is able to detectthe spatial coordinates in space of said tool (11).
 7. The method ofclaim 1 wherein said sensor (6) comprises a vision system.
 8. The methodof claim 1 wherein said sensor (6) comprises a system of inertialsensors arranged to determine the spatial coordinates of said assemblymeans.
 9. The method of claim 1, wherein the graphic instructioncomprises a symbol.
 10. A method for assisting an operator in aproduction environment for use in manual assembly operations on aworkpiece positioned in a work area, the method including a programmabledevice having a sensor, a lighting device, an input device, and anelectronic control system in communication with the sensor, the lightingdevice and the input device, the method comprising: recording a learningsequence comprising: continually monitoring by the sensor the work areato detect the spatial coordinates of an assembly means positioned in thework area; the operator positioning the assembly means in the work areaat a first position having first spatial coordinates; projecting by thelighting device a visual graphic instruction at the first spatialcoordinates; actuating the input device by the operator to record thefirst position; the operator moving the assembly means in the work areafrom the first position to a second position having second spatialcoordinates different than the first spatial coordinates; the lightingdevice projected visual graphic instruction continually follows themovement of the assembly means between the first position and the secondposition; actuating the input device by the operator to record thesecond position; storing the spatial coordinates of the assembly meansat the recorded first position, movement of the assembly means betweenthe recorded first position and the second position, and the recordedsecond position in the electronic control system; and subsequentlyassisting a work cycle sequence by the operator in performing the manualassembly operations on the workpiece using the stored learning sequence.11. The method of claim 10, wherein assisting the work cycle sequencefurther comprises: continually monitoring by the sensor the work area todetect a presence and the spatial coordinates of the assembly means inthe work area; projecting by the lighting device the graphic instructionat the first spatial coordinates at the recorded first position;positioning by the operator the assembly means at the projected graphicinstruction at the first spatial coordinates at the recorded firstposition; detecting by the sensor the spatial coordinates of theassembly means positioned in the work area; verifying by the electroniccontrol system through comparison of the first spatial coordinates atthe recorded first position and the detected spatial coordinates of theassembly means positioned in the assembly area that the assembly meansis positioned at the recorded first position; and actuating by theoperator the input device verifying the assembly means is positioned atthe recorded first position.
 12. The method of claim 11, whereinsubsequent to the actuating by the operator the input device verifyingthe assembly means are positioned at the recorded first position, theassisting the work cycle sequence further comprises: projecting by thelighting device the graphic instruction at the second spatialcoordinates at the recorded second position; positioning by the operatorthe assembly means at the projected graphic instruction at the secondspatial coordinates at the recorded second position; detecting by thesensor the spatial coordinates of the assembly means positioned in thework area; verifying by the electronic control system through comparisonof the second spatial coordinates at the recorded second position andthe detected spatial coordinates of the assembly means positioned in theassembly area that the assembly means is positioned at the recordedsecond position; and actuating by the operator the input deviceverifying the assembly means is positioned at the recorded secondposition.
 13. The method of claim 11, wherein the graphic instructioncomprises a symbol.
 14. The method of claim 11, wherein the lightingdevice is operable to project a first graphic instruction at therecorded first position and a separate independent second graphicinstruction, wherein following detecting by the sensor of the spatialcoordinates of the assembly means positioned in the work area; themethod further comprises: projecting by the lighting device the secondgraphic instruction at the detected spatial coordinates of the assemblymeans positioned in the work area.